LATEST TRENDS IN

WELDING PROCESSES
AND CONSUMABLES

BY
M. P. DHANUKA
GEE Limited
Thane – 400 064
1
Introduction :

 Welding today, has become one of

the most important tools for efficient
maintenance of plants and quality
fabrication in industry.

2
 It has come to play a vital role in the
growth and development of a variety of
important sectors of the economy such
as thermal, hydro, nuclear and wind
power generation, petrochemicals, off-
shore drilling, steel plants, industrial
machinery, heavy engineering, ship
building, transportation fertilisers, oil &
water pipelines, etc.

3
 Welding Technology today is not
merely a joining method but it is
effectively used for cladding, hard-
surfacing, cutting and for variety
of other applications.

4
 Most of the time welding engineers or
inspectors think that weld metal quality
depends largely on either skill of the
welder or on the quality of welding
consumables used for depositing weld
metal. However, there is a third important
variable/factor which does contribute to
the quality of deposited weld metal and
that important variable/factor is quality or
type of power source used, while
depositing the weld metal.

5
 In order to derive maximum benefits
in terms of productivity and quality,
welding engineers/supervisors should
study the latest trends in welding
processes and consumables available
for various arc welding processes, so
that they can derive maximum benefits
and can become globally competitive.

6
TRENDS IN WELDING CONSUMABLES :

 Last year i.e. in the year 2004-2005, steel

production in our country was about 35.0
million tons.
 However, consumption pattern of the steel
shows that growth is more confined to long
products, which are mainly used for
construction activities. As far as welding is
concerned, there has been growth of about 6
to 8% as compared to pervious year.
7
Last few years have seen distinct change
towards MIG/MAG welding from SMAW
(MMAW) process. However, the change is
confined to large and medium fabricators.
The consumption figures of welding
consumables available form the industries
are tabulated in Table 1.

8
 TABLE 1
(All Figures in Metric Tons)

Sr. Manual MIG/MAG Submerged TIG Total

No Metal Arc Welding Arc Welding
. Welding Welding

1. Deposited 127000 50000 15000 3000 195000

weld metal

(2004-
2005)

2. Electrodes/ 200000 52000 15000 3000 270000

Wire
(2004-2005)

9
During 2004-2005, in our country, about 64
percent of weld metal was deposited by
using SMAW process whereas about 26
percent weld metal was deposited by using
MIG/MAG process. The trend is obviously
to use more and more MIG/MAG process,
using solid, flux cored or metal cored wires
for increasing overall productivity in the
shopfloor.

10
TRENDS IN SMAW WELDING CONSUMABLES
With the global competition, our fabricators have
become more quality conscious. Many of them have
received ISO-9000 certification and ASTM-U
Stamp. The welding engineers stipulate their
requirements of welding consumables by preparing
specifications, which are usually based on ASME
Section II Part ‘C’ specification.

 
11
The latest trends of welding consumables observed
are as under :
IMPROVED QUALITY OF SOLID WIRES FOR
MIG/MAG WELDING
Few manufacturers of welding wires, produce CO2
grade wires, grade ER 70S-6 in which copper coating
is carried out by electroplating process. Such wires
when used give following advantages :
a)   Uniform copper coating – which results in better
feedability.
b)   No flaking of copper because adherance of copper on
the wire is 100%.
c)   Current transfer is more consistant. 12
 USE OF METAL CORED WIRES FOR MIG/MAG
WELDING
For welding high tensile, low alloy and creep resisting
steels, welding engineers have started switching over
to metal cored wires instead of fluxcored wires.

13
Distinct advantages of Metal cored wires are as under :

a) Possible to produce small batch.

b) Deposited weld metal has lower impurities
c) Arc stability is excellent and wetting characteristic
of the weld to the parent metal is very good which
result in 100% radiographic quality welds.
d) Lower diameter metal cored wires can be used in
(1.0 mm dia) positional welding.

14
FLUX CORED WIRES FOR MIG/MAG WELDING :
In the recent years, depending upon applications, flux
cored wires have been developed for welding low-
alloy high tensile steels, weathering steels, cryogenic
steels, etc. These wires are usually rutile as well as
basic type and are available in diameter 1.20 mm or
1.60 mm.

15
FLUX CORED WIRES FOR HARDFACING
APPLICATION OR FOR RECLAMATION
WELDING :
Variety of flux cored wires either self-shielded or
gas shielded are now being used in increasing
quantity for hardfacing /reclamation welding. Few
examples are reclamation of cement mill rolls,
pulleys. Caterpillar tracks rollers, crusher jaws,
excavator parts, etc.

16
 CELLULOSIC ELECTRODES FOR PIPE LINE
WELDING

Even today for laying cross-country pipelines,

cellulosic electrodes are preferred. These
consumables help to increase the productivity and are
now supplied in tin containers, which are
hermetically sealed.

17
Such containers retain moisture in the flux coating of
electrodes, which is an essential feature for obtaining
desired penetration and performance while welding.
For welding of cross-country pipelines, the pipe line
designers have started specifying following
cellulosic electrodes for welding:
a) E7010-P1
b) E8010-P1
c) E8010G
d) E9010G

18
EX010-P1 (pipeline) electrodes have been designed
primarily for welding typical high strength, pipe butt
joints in the vertical welding position with
downward or upward progression. These specially
formulated cellulosic electrodes are best suited for
achieving full penetration and radiographic quality.
Usually E7010 - P1 is recommended for welding of
APl-5L-X52 and APl-5L-X65 piping assemblies
respectively. Even today, few fabricators use
cellulosic electrodes, type E7010-G and E8010-G for
similar applications.

19
 HYDEROGEN CONTROLLED, MOISTURE
RESISTANCE ELECTRODES :
With the revision of AWS/SFA 5.1 and AWS/SFA 5.5
specifications, welding engineers could be more
specific while writing their requirements of welding
consumables. The revised specifications allow users
to mention what type of hydrogen controlled
electrodes are required and whether they are looking
for moisture resistant type basic coated electrodes.
 

20
TABLE 2, gives information on how welding engineers
could stipulate their requirements, depending on the
job specifications/ critical application.

21
Welding consumables manufacturers usually supply
moisture resistant electrodes in hermetically sealed
tin containers or in vacuum pouches. The use of
moisture resistant electrodes eliminate expensive
drying before use and eliminate or reduce post weld
heat treatment for many applications.

22
E7018/E7018-1ELECTRODES FOR OFF-SHORE
FABRICATIONS –PROCESS PLATFORMS
INVOLVING WELDING OF NACE STEEL.
TABLE 2
Type of basic coated Same type with Same type with
electrode requirements of requirements of
diffusible hydrogen diffusible hydrogen
in the weld metal in the weld metal and
  moisture resistant
coating specification
E 7018 E7018-H4 E 7018-H4R
E 7018-H8 E 7018-H8R
E 7016-1 E 7016-1 H4 E 7016-1 H4R
E 7016 –1 H8 E 7016-1 H8R
E 8018-B2 E 8018-B2 H4 E 8018-B2 H4R
E 11018 M E 11018M H4 E 11018M H4R 23
NACE specification for such special types of
E7018/E7018-1 electrodes is given in Table No. 3
TABLE 3
Type of Max. ‘Mn’ Max. ‘S’ Max. ‘P’
electrodes Content content Content
(%) (%)
 

E 7016 )
E 7016-1 )
E 7018 ) -1.40 0.010 0.012
E 7018-1 )
)

24
E7018/E7018-1 ELECTRODES WITH HIGH IMPACT
VALUES AT SUBZERO TEMPERATURES :
For specific applications such as critical parts of steel
plants, off-shore platforms, few designers stipulate very
high impact requirements at sub-zero temperatures.
These requirements are given in Table 4.
TABLE 4
Type of Electrodes Impact requirements at sub –zero
temperature
E 7016-1 100 Joules at minus 460C
 
E 7018-1 100 Joules at minus 460C

25
Designers are of the opinion that the weld metal deposited
from such high quality electrodes, has unique property
of ‘resistance to ageing’ and thus under severe service
conditions, the weld metal does not fail and thus helps
to achieve continuous desired productivity year after
year.
 

26
NEWLY DEVELOPED WELDING CONSUMABLES
FOR WELDING OF T/P 92 MATERIAL.
 

27
Designers of power plants have started recommending
T/P 92 grade alloyed steel in place of T/P 91 for
following benefits :
a)  30% gain on the admissible stress at 6000C .
b)  A significant reduction in thickness can be obtained
weight reduction given benefit of overall cost
reduction of the power plant.
C) Time of fabrication can be reduced.
d) Improved creep properties as well as toughness
properties.
28
 CHEMICAL ANALYSIS OF ASTM
A 355 – GRADE P 92.

     V – 0.15-0.25
     C - 0.07-0.13
     N – 0.03-0.07
     Mn – 0.30-0.60
     Ni – 0.40 max
     S – 0.010 max
     Al – 0.04 max
     P – 0.020 max
     Nb – 0.04-0.09
     Si – 0.50 max
     W – 1.50-2.00
     Cr – 8.50-9.50
     B – 0.001-0.006
     Mo – 0.30-060
29
MECHANICAL PROPERTIES OF P/T –92 MATERIAL.
UTS – 620 Mpa Minimum
0.2% Proof Stress – 440 Mpa Minimum
Elongation – 15% Minimum
(L=5d)
 

30
NEWLY DEVELOPED WELDING CONSUMABLES
FOR P92/T-92
Basic type electrode E9018-G has been developed with
controlled BORON content in the weld metal

31
CHEMICAL PROPERTIES OF THE WELD METAL
(E 9018-G) are as under :

     C - 0.10      Nb – 0.05

     Si - 0.30 
    N – 0.04
     Mn - 1.0
     W – 1.7
     Cr – 9.0
     B – 0.003
     Mo – 0.50
     Al – 0.010 max
     V – 0.2
     Cu – 0.05 max
     Co – 1.0

32
 SAW WELDING CONSUMABLES FOR
P92/MATERIAL.
Suitable metal cored wire Aluminate – Fluoride basic
type flux have been developed.

33
 DEPOSITED WELD METAL CHEMISTRY IS AS
UNDER (SAW) :

 C – 0.10  Nb – 0.05
 Si – 0.30  N – 0.04
 Mn – 1.0  W – 1.7
 Cr – 9.0  B – 0.002
 Mo – 0.50  Al – 0.02 max
 Co – 1.0  Cu – 0.05 max
 V – 0.2
34
Development of Tig wire for welding P-92/T-92.
Metal Cored wire type ER 90S-G has been developed.
The wire deposits weld metal having following
chemical and mechanical properties :
Weld Metal Analysis (Typical)
 C – 0.10
 V – 0.02
 Si – 0.50
 Nb – 0.05
 Mn – 1.0
 N – 0.04
 Cr – 9.0
 W – 1.70
 Mo – 0.50
 B – 0.002
 Co – 1.0
 Al – 0.010 max
 Cu – 0.05 max 35
 Welding consumables for T/P-23 and T/P-24.
SMAW and Tig welding consumables have been
developed for welding T/P-23 and T/P-24 material.
Weld metal chemistry for T/P-23 of the electrode
E 9015-G is as under :
 C – 0.05  W – 1.4
 Si – 0.40  Nb – 0.01
 Mn – 0.50  X factor less than 15
 Cr – 2.15 PPM.
 Mo – 0.50  J factor less than 120.
 Ni – 0.40.
 V – 0.25 36
Weld metal chemistry suitable for T/P-24 of the
electrode E 9015G is as under :
 C – 0.07  Ti – 0.06
 Si – 0.50  B – 15-70 PPM
 Mn – 0.50  X factor less than
 Cr – 2.40 10 PPM.
 Mo – 1.0  J factor less than
 Ni – 0.08 120.
 V – 0.25
37
 Tig wires and SAW welding consumables for T/P-
23 and T/P-24.
 Suitable Tig wires and SAW wire and flux
combination have been developed for welding T/P-
23 and T/P-24 material.
 SAW Welding Consumables are classified as
AWS/SFA 5.23 : F9P2EGR-G

38
 Welding consumables for Automobile Catalytic
Converter
For refining exhaust fumes, the catalytic converters
are arranged closer to the Engine with the result, that
the increased temperature of the exhaust fumes
improves the refining effect. (Euro 4)

39
 New GMAW consumables for ferritic base material.
(1.4509, 1.4511, 1.4512) are as under :

a) ER 430 (Mod) surface scaling resistance upto 9000C

wire analysis
 C – 0.02 max
 Si – 0.50
 Cr – 18.0
 Nb – 12XC minimum
b) EN 12072 : GZ 18 TiL

40
Surface scaling resistant upto 9000C
Wire Chemistry

 C – 0.03
 Si – 0.80
 Mn – 0.80
 Cr – 18.0
 Ti – 12XC minimum

41
Welding consumables for SUPERMARTENSITIC 13%
Chromium steel (APl grade X-80)
Base Metal (Typical)

 C – 0.012  Cu – 0.40
 Si – 0. 26  N – 0. 01
 Mn – 1.0  UTS– 860 Mpa
 Cr – 12.5  YS– 643 Mpa
 Mo – 0.6  Elongation – 27%
 Ni – 4.4
42
 GTAW Consumable for welding Supermartensitic
ferritic steel

Typical all weld Mechanical Properties

metal analysis as welded
 C – 0.013  UTS – 1050 Mpa
 Si – 0. 50  YS – 900
 Mn – 0.60  Impact at –300C –
 Cr – 12.5 90 joules.
 Mo – 2.8
 Ni – 6.3
 N – 0.013 43
 Superaustenitic stainless steel welding consumables
have been developed for GTAW and GMAW
processes weld metal has
 Excellent resistance against chloride containing
media.
 High strength of the weld metal because of its high
Nitrogen content (0.40%).
 Highest critical pitting resistance.
Applications :
 Offshore Industry
 Flue gas desulphurisation.
 Pulp and paper manufacturers. 44
 Weld Metal Analysis

Typical all weld Mechanical Properties

metal analysis as welded
 C – 0.010  UTS – 810 Mpa
 Mn – 5.10  0.2 Proof Stress –
 Cr – 24.14 530 Mpa
 Mo – 4.94  Elongation – 43%
 Ni – 21.80  PRE – 46.8
 Cu – 0.90
 N – 0.40 45
 CONCLUSIONS
1) Indian fabricators are slowly switching over to GMAW process
from SMAW process.
2) At present about 26% of the total weld metal deposited is by
using GMAW process.
3) Consumption of solid wires for fabrications in GMAW process
is maximum (more than 90%)
4) Metal cored wires are finding increasing applications specially
areas where quality is most important.
5) Comparatively it is easy to manufacture alloyed grade of Metal
cored wires.
6) Special grades of metal cored wires are used for SAW process
for example welding of P/T-92 material.
46
7) Weld metal deposited using Metal cored wire with recommended
shielding gas is superior because overall toughness properties
are superior.
8) Few fabricators have started using moisture resistant, vacuum
packed, E 7018-1 H4R electrodes for critical applications.
Overall deposition rates for such electrodes is quite high since it
eliminate expensive redrying before use.
9) SMAW, Tig and SAW welding consumables have been
developed for following recently developed creep resistance
steels:
a) P 91 / T 91
b) P 911 / T 911
c) P 92 / T 92
d) T/P 23
e) T/P 24 47
10) For welding catalytic converter of improved grade of base metal
type 1.4509, 1.4511, 1.4512, GMAW & FCAW wires such as E
430 (Mod) and GZ 18 TiL have been developed.
11) For welding Supermartensitic 13% chromium steels, GTAW,
GMAW and SAW welding consumables have been developed.
The weld metal of deposited from such consumables has very
low carbon content, less than 0.020% and has excellent impact
properties at –400C.
These consumables find applications for welding pipes of the
off-shore industry.
12) For welding Superaustenetic stainless steels, special welding
consumables (GTAW and GMAW) have been developed. The
weld metal deposited from such consumables has about 4.5%
Molybdenum and 0.40% Nitrogen content.
48
The deposited weld metal of such electrode has
a) Excellent corrosion resistance against chloride containing
media.
b) Higher strength because of 0.40% Nitrogen.
c) Higher PRE.
Therefore above electrodes finds applications in off-shore
industry as well as plants for flue gas desulphurisation, pulp,
and paper manufacturers etc.

49
THANK YOU

50